Isuzu_Rodeo_Rodeo_Sport_1997-2004

Cylinder Head Cover

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Removal & Installation



3.2L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner duct assembly.

    Click image to see an enlarged view

    Fig. View of the PCV hose connector (1), Intake Air Temperature (IAT) sensor (2), air cleaner duct assembly (3), air cleaner element (4) and Mass Airflow (MAF) sensor (5)-3.2L Engine

  4.  
  5. Disconnect the Positive Crankcase Ventilation (PCV) hose.
  6.  
  7. Remove camshaft angle sensor connector.
  8.  
  9. Remove ground cable fixing bolt on cylinder head cover.
  10.  
  11. Remove the ignition coil connector and ignition coil:
    1. Disconnect the three connectors from the ignition coils.
    2.  
    3. Remove harness bracket bolt on cylinder head cover.
    4.  
    5. Remove fixing bolts on ignition coils.

      Click image to see an enlarged view

      Fig. View of the ignition coil connector (1), bolt (2) and ignition coil assemblies (3)-3.2L engine

    6.  

  12.  
  13. Remove the fuel injector harness bracket mounting bolt.
  14.  
  15. Remove the eight mounting bolts, then remove the cylinder head cover.
  16.  
  17. Clean the cylinder head cover mating surfaces.
  18.  

To install:

  1. Install cylinder head cover, as follows:
    1. Apply sealant (TB-1207B or equivalent) of bead diameter 2-3 mm at eight place of arched area of camshaft bracket on front and rear sides.
      WARNING
      The cylinder head cover must be installed with in 5 minutes after sealant application to prevent hardening of sealant.

    2.  
    3. Tighten the cylinder head cover bolts 80 inch lbs. (9 Nm).

      Click image to see an enlarged view

      Fig. Left side cylinder head cover tightening sequence-3.2L engine

    4.  

  2.  
  3. Install the fuel injection harness bracket and tighten the bolt(s) 80 inch lbs. (9 Nm).
  4.  
  5. Connect the ignition coil connector and ignition coil, then tighten bolt to 35 inch lbs. (4 Nm).
  6.  
  7. Connect the negative battery cable and tighten bolts to 8 inch lbs. (9 Nm).
  8.  
  9. Connect the camshaft angle sensor connector.
  10.  
  11. Install the PCV hose.
  12.  
  13. Install air cleaner duct assembly.
  14.  

3.5L Engine
Left Side
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine cover from the dowels on the common chamber.
  4.  
  5. Disconnect the Positive Crankcase Ventilation (PCV) hose.
  6.  
  7. Remove the ground cable fixing bolt from the cylinder head cover.
  8.  
  9. Remove the ignition coil connectors and ignition coil. Refer to the Engine Electrical Section for details.
  10.  
  11. Remove timing belt cover fixing bolt from the cylinder head front side.
  12.  
  13. Remove the 8 cylinder head cover mounting bolts.
  14.  
  15. Thoroughly clean the sealing surfaces of cylinder head and cylinder head cover to remove oil and sealant materials completely.
  16.  

To install:

  1. Apply a 2-3 mm bead of sealant (TB-1207B or equivalent) at four place of arched area of camshaft bearing cap on front and at four place of rear cam end plugs.
    NOTE
    The cylinder head cover must be installed within 5 minutes of applying the sealant to avoid hardening of the sealant.



    Click image to see an enlarged view

    Fig. Sealant application locations-left and right sides shown

  2.  
  3. Install cylinder head cover. Tighten the retaining bolts, in sequence, to 6.6 ft. lbs. (9 Nm)

    Click image to see an enlarged view

    Fig. Left cylinder head cover bolt tightening sequence-Note: 1. Long bolt without rubber mount

  4.  
  5. Install the timing belt cover bolt to the cylinder head front side. Tighten to 14 ft. lbs. (19 Nm).
  6.  
  7. Attach ignition coil connector and ignition coil, then tighten the retaining bolts to 5.9 ft. lbs. (8 Nm).
  8.  
  9. Connect the PVC hose.
  10.  
  11. Install the engine cover, mating it with the dowels.
  12.  
  13. Connect the negative battery cable.
  14.  

Right Side
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine cover from the common chamber.
  4.  
  5. Disconnect the ventilation hose from the cylinder head cover.
  6.  
  7. Disconnect three ignition coil connectors from ignition coils and remove harness bracket bolts on cylinder head cover, then remove the ignition coil mounting bolts from ignition coils and remove the coils.
  8.  
  9. Remove the water pipe bracket mounting from the cylinder head cover rear side.
  10.  
  11. Remove the timing belt cover fixing bolt from the cylinder head cover front side.
  12.  
  13. Remove the 8 cylinder head cover mounting bolts.
  14.  
  15. Thoroughly clean the sealing surfaces of cylinder head and cylinder head cover to remove oil and sealant materials completely.
  16.  

To install:

  1. Apply a 2-3 mm bead of sealant (TB-1207B or equivalent) at four place of arched area of camshaft bearing cap on front and at four place of rear cam end plugs.
    NOTE
    The cylinder head cover must be installed within 5 minutes of applying the sealant to avoid hardening of the sealant.



    Click image to see an enlarged view

    Fig. Sealant application locations-left and right sides shown

  2.  
  3. Install cylinder head cover. Tighten the retaining bolts, in sequence, to 6.6 ft. lbs. (9 Nm)

    Click image to see an enlarged view

    Fig. Right cylinder head cover bolt tightening sequence

  4.  
  5. Install the water pipe bracket fixing bolt to the rear cylinder head and tighten the bolts to 14.8 ft. lbs. (20 Nm).
  6.  
  7. Attach the ignition coil connectors, then install the ignition coil and tighten the mounting bolts to 5.9 ft. lbs. (8 Nm).
  8.  
  9. Connect the ventilation hose to cylinder head cover.
  10.  
  11. Install the engine cover mating with the dowels.
  12.  
  13. Connect the negative battery cable.
  14.  

 
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